TensorDS DL

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<ul><li><p> A Guide to Using </p><p>Tensor DS and Tensor DL Drive with Tools Talk DS/DL </p><p>Atlas Copco Tools and Assembly Systems AB</p><p>Edition 3 Atlas Copco Tools and Assembly Systems AB - 9836 2050 01 Page 1 (145) 2003-09 </p></li><li><p> Contents </p><p>1. SAFETY INSTRUCTIONS............................................................................................................ 5 2. INTRODUCTION ........................................................................................................................ 7 </p><p>2.1 General .................................................................................................................................7 2.2 DS/DL Drive ........................................................................................................................7 2.3 System Functionality...........................................................................................................9 2.4 ToolsTalk DS/DL...............................................................................................................10 </p><p>3. DS/DL DRIVE ........................................................................................................................ 11 3.1 Connectors DS ...................................................................................................................11 3.2 Connectors DL...................................................................................................................12 3.3 Inputs/Outputs Schematic ................................................................................................13 3.4 Installation of DS hardware .............................................................................................21 3.5 Installation of DL hardware.............................................................................................22 3.6 Installing new software into the DS/DL Drive................................................................23 3.7 DS Drive Dimensions ........................................................................................................24 3.8 DL Drive Dimensions ........................................................................................................25 3.9 Display / Key Pad DS Drive..............................................................................................26 3.10 Display / Key Pad DL Drive .............................................................................................27 3.11 Different models of DS/DL Drive.....................................................................................29 3.12 Functions, D302 / D303 and D312 / D313........................................................................31 3.13 Functions, D312 / D313 only.............................................................................................34 3.14 Key Pad Functions ............................................................................................................35 3.15 Remote Start ......................................................................................................................40 3.16 Inputs and Relays ..............................................................................................................41 </p><p>4. PROGRAMS............................................................................................................................. 43 4.1 Selection of program .........................................................................................................43 4.2 Tightening strategies .........................................................................................................47 4.3 Special Functions...............................................................................................................53 </p><p>5. TOOLSTALK DS/DL .............................................................................................................. 59 5.1 Installation .........................................................................................................................59 5.2 Working in Tools Talk......................................................................................................63 5.3 Programming Window .....................................................................................................72 5.4 Run Window......................................................................................................................80 5.5 Torque Tuning Window ...................................................................................................81 </p><p>3 </p></li><li><p>Contents </p><p>5.6 Configuration Window, Tensor DS &amp; DL ......................................................................85 5.7 Configuration Window, Tensor DL only ........................................................................89 5.8 Diagnostics .........................................................................................................................95 </p><p>6. PROGRAMMING...................................................................................................................... 99 6.1 Hints ...................................................................................................................................99 6.2 Full Programming of pset...............................................................................................103 6.3 Quick Programming .......................................................................................................108 6.4 Auto Set ............................................................................................................................109 6.5 Torque Tuning.................................................................................................................110 6.6 Configuration...................................................................................................................112 </p><p>7. ACCESSORIES....................................................................................................................... 117 7.1 RE Alarm .........................................................................................................................118 7.2 Selector, only for D312 / D313........................................................................................120 7.3 I/O Expander ...................................................................................................................125 7.4 IR Key ..............................................................................................................................126 </p><p>8. TROUBLE SHOOTING ........................................................................................................... 129 8.1 Error Messages in ToolsTalk DS/DL.............................................................................129 8.2 Error codes on Drive.......................................................................................................130 8.3 What might have happened........................................................................................137 </p><p>9. TECHNICAL SPECIFICATIONS .............................................................................................. 141 9.1 DS Drive ...........................................................................................................................141 9.2 DL Drive...........................................................................................................................142 9.3 Tools Talk DS/DL............................................................................................................143 </p><p>10. ABBREVIATIONS................................................................................................................... 145 </p><p>4 </p></li><li><p>Safety Instructions </p><p>1. Safety Instructions WARNING Read and understand all instructions. Failure to follow all the instructions listed below may result in electric shock, fire and/or serious personal injury. SAVE THESE INSTRUCTIONS IMPORTANT All locally legislated safety rules with regard to installation, operation and maintenance must be respected at all times. Refer installation and servicing to qualified personnel only. Work Area Keep your work area clean and well lit. Cluttered benches and dark areas invite accidents. Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases, or dust. Power tools create sparks, which may ignite dust or fumes. Keep bystanders, children, and visitors away while operating a power tool. Distractions may cause you to lose control. Electrical Safety Earthed tools must be plugged into an outlet that has been properly installed and earthed in compliance with all relevant codes and ordinances. Never remove the earthing prong or modify the plug in any way. Do not use any adapter plugs. Check with a qualified electrician if you are in any doubt as to whether the outlet is properly earthed. Should the tools suffer electronic malfunction or breakdown, earthing provides a low resistance path to carry electricity away from the user. Applicable only to Class I (earthed) tools. THIS MUST BE EARTHED! Avoid body contact with grounded surfaces such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is grounded. Don't expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. This instruction does not apply to tools classified as watertight or splash proof. For minimum electrical interference, place the instrument far away from possible sources of electrical noise, e.g. arc welding equipment etc. Do not abuse the cord. Never use the cord to carry the tools or pull the plug from an outlet. Keep cord away from heat, oil, sharp edges or moving parts. Replace damaged cords immediately. Damaged cords increase the risk of electric shock. Personal Safety Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use tool while tired or under the influence of drugs, alcohol, or medication. A momentary lapse in concentration whilst operating power tools may result in serious personal injury. Dress properly. Do not wear loose clothing or jewellery. Tie long hair back. Keep your hair, clothing, and gloves away from moving parts. Loose clothes, jewellery, or long hair can be caught in moving parts. Avoid accidental starting. Be sure switches are in the off position before plugging in. Carrying tools with your finger on the switch or plugging in tools that have the switch set to on invites accidents. </p><p>5 </p></li><li><p>Safety Instructions </p><p>Remove adjusting keys or switches before turning the tool on. A wrench or a key that is left attached to a rotating part of the tool may result in personal injury. Do not overreach. Keep proper footing and balance at all times. Proper footing and balance enables better control of the tool in unexpected situations. Tool Use and Care Use clamps or other practical means to secure and support the work piece to a stable platform. Holding the work by hand or against your body is unstable and may lead to loss of control. Do not force the tool. Use the correct Atlas Copco Tensor tool for your application. The correct tool will do the job better and safer at the rate for which it is designed. Do not use tool if switch does not work. Any tool that cannot be controlled by the switch is dangerous and must be repaired. Disconnect the plug from the power source before making any adjustments, changing accessories, or storing the tool. Such preventive safety measures reduce the risk of starting the tool accidentally. The mains plug is considered to be a disconnecting device. Disconnect the tool from the mains by pulling the plug from the socket in order to cut the power. Store tools out of reach of children and other untrained persons when not in use. Tools are dangerous in the hands of untrained users. Check for misalignment or binding of moving parts, damage, and any other condition that may affect tool operation. If damaged, have the tool serviced before using. Poorly maintained tools cause many accidents. Only use accessories that are recommended by the manufacturer for your model. Accessories that may be suitable for one tool may become hazardous when used on another tool. SERVICE Tools should only be serviced by qualified repair personnel. Service or maintenance performed by unqualified personnel could exposes users to serious personal injury. When servicing a tool, only use original replacement parts. Use of unauthorised parts or failure to follow Maintenance Instructions may create a result in electric shock or personal injury. CAUTION There is a danger of explosion if batteries are incorrectly replaced. Replace only with the same or equivalent type recommended by the equipment manufacturer. Discard used batteries in accordance with manufacturer's instructions. </p><p>6 </p></li><li><p>Introduction </p><p>2. Introduction 2.1 General Tensor S electric nutrunners brought a minor revolution to controlled tightening. They are now the industry standard for critical joints with safety applications, though not economically feasible for use on joints throughout a whole plant. </p><p>Tensor DS is the alternative that lets you apply the benefits of advanced electric systems for controlled tightening on all the joints in your product. With Tensor DS you do not need to depend on mechanical devices or human repeatability to safeguard your joint integrity. Tensor DS means you can afford Tensor levels of operator acceptance, operator feedback, productivity, dependability, low service cost, multi-torque and joint control for all your tightening operations. </p><p>Tensor DL is the electric tool choice for small screw assembly. Its small size and good performance will increase productivity and reduce costs in your assembly operations. Tensor DL incorporates all the functionality of the Tensor DS, e.g. operator guidance, process control and rundown monitoring functionality. </p><p>2.2 DS/DL Drive The Tensor DS/DL electric nutrunners and screwdrivers are extremely fast and light. The Tensor DS/DL Drive does not use a torque transducer, instead it uses the unique Atlas Copco DigiTork system, proven to achieve excellent repeatability. </p><p>The Drive is programmed using the ToolsTalk DS/DL programming tool wich runs on a normal Windows based pc or lap top. </p><p>It is also possible to program the drive to a limited extend directly on the key pad, see section Key Pad Programming, chapter 3.10. </p><p>The Tensor DS Tools come in three different motor sizes DS4, DS7 and DS9, and can handle torques from 1 to 2000 Nm. Each tool requires its own drive unit. </p><p>Tensor DL can handle torques from approx 1 to 10 Nm. Each tool requires its own drive unit. </p><p>7 </p></li><li><p>Introduction </p><p>Two different Drive versions There are two different functionality levels of the Tensor DS/DL system, the D302 / D303 Basic drive and the D312 / D313 Advanced drive with the possibility to program up to ten...</p></li></ul>